Question about Coleman Powermate 60 Gallon Air Compressor

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Air compressor had sparks shooting. We took it apart and think we need new brushes. Any suggestions onto where we can find the right ones?

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An electric motor repair shop can match them up and will sell then to you with no problem.

Posted on Dec 19, 2008

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I have a porter cable pancake compressor 135 and it's sparking and smoking . What do you think it is?

Heavy sparking at brushes indicates shorted armature or short in field. Examine commutator bars, should look dark gray to black but very smooth. If scratched or pitted most likely end of life. If not too bad could be weak brush springs or worn brushes. Brushes should be at least 1/2 to 3/4 in in length. If commutator and brushes good , suspect field. Good luck

Sep 28, 2016 | Porter Cable Air Tools & Compressors

1 Answer

I have a DeWalt D55168 type 3 air compressor that the motor brushes keep sparking and smoking.

If the compressor is relatively new and performs well, it is probably not an issue. Brushes always spark on the commutator but without seeing the extent of the sparks it is hard to tell for certain if it is "too much" or not. I wouldn't expect any significant smoke from the brushes and commutator or the armature unless it is brand new and the oils from manufacturing are being burned off. If it is a very old machine, it is possible the armature is shorted out and needs to be replaced.

If, on the other hand, it is not brand new, but a couple years old, has had use, but not heavy and continuous and you just see small sparks coming from the brushes, then it is probably ok. If the sparks seem larger than what you are accustomed to and you are seeing smoke coming from the motor at all (presuming it is not the brand new situation noted above) then the armature may be starting to short out and/or the windings in the motor may be starting to burn out. Electric motors that are used within their design constraints (not overloaded, not run on low voltage, not run continuously if not designed for that use, not overheated) do not tend to burn out. However, if the windings get covered with sawdust (which insulates them), you run the compressor continuously for hours on end, day after day, especially in a hot environment and/or with low voltage, then you have probably overheated the windings and the motor is burning out. For a compressor of this size and quality, it would likely cost more to have the motor rewound than it cost to replace the compressor. Also, if it has failed from overly hard use, rewinding the motor will not prevent another burn-out, you need a larger, more durable compressor.

Aug 10, 2012 | Air Tools & Compressors

1 Answer

The compressor motor is getting hot, I removed the cover and one of the brushes is shooting sparks when the motor is turned on, the brushes seem to have plenty of pad left and seem to be aligned properly...

If there were a problen with the field or the armature, both brushes would make fire(look at both sides of each brush for spark). Sparking is normal, however heavy blue fire would indicate problem. When one brush is making unusual sparks I would suspect that the spring applying pressure to the brush against the armature has failed. Look at both brush springs and see if there is a color difference or feel the pressure that the springs are exerting. They should be equal. You can push on the brush slightly with wood or plastic tool. To see if there is an improvement. Replace parts as needed. Test the motor with amp meter and compare to amp rating on plate to be sure that there is not a problem with motor. If amp draw is slighly high, check for tight bearing, leaking head gaskets/reed valves or leaking checkvalve at the tank. Good luck.

Sep 09, 2011 | Dewalt D55168 1.8 HP Wheeled Portable...

1 Answer

My compressor since new, at times will leak air from under the cover while the pump is running and after it cuts off. Sometimes works perfect. Took it apart and could not see a problem. Any suggestion

There is a check valve that is wired into the on off switch. If there are no air leaks when the unit is not running then it is normal. The other possibility is a leak where the rubber hose conncets to a metal tube inside the plastic housing.

Jul 13, 2011 | Porter Cable C2002 150 Psi 6 Gal...

1 Answer

I have recently come onto an air compressor that does not work. i have not yet had a chance to take it apart and look inside. when i pug it in and flip the switch nothing happens. i know i dont have a lot...

This is a fairly trouble free unit. Most of the compressors in for repair in that model range are suffering from low pressure due to worn piston ring. Some however have had broken wire at pressure switch, on/off switch and brushes pulled away from the commutator or burned brush wire. All easy repair and parts are available from several locations or use universal parts. Good luck

Apr 15, 2011 | Porter Cable C2002 150 Psi 6 Gal...

2 Answers


most likely the regulator is shoot. But also try checking for leaks with dish soap and water in a spray bottle.

Mar 06, 2011 | Clarke Power Products Inc AC2001 2HP 4...

1 Answer

I need new brushes for Powermate Air Compressor motor. Where can I purchase them or do I need to have a Technician install? Model #CL0551109 Thank You J.L. Brooks

Brushes are not listed as a replacement part for your compressor. Not to worry because universal brushes are available at tool repair shops, hardware stores and ebay. Measure your brush and order same size or slightly larger and sand to fit. Dont worry too much about the length of brush as they can be shorter than factory and still work fine (just longer than worn brushes). Some motors have a spring pushing brush onto armature and others utilize the spring attached to brush to make contact. You can cut off wire from back of brush if needed, however if your motor needs brushes with spring attached, find close match and solder your old contact and spring to new brush. Also check for other problems because brushes should last the life of motor on your unit. Good luck

Aug 17, 2010 | Coleman Powermate 27 Gallon Air Compressor

1 Answer

Motor starts and stops at short intervels with large amounts of spark on one side of brushes.

your brushes are worn out and have probably ruined the stator commutator rings, you can try new brushes,but i believe its too late

Oct 19, 2009 | Coleman Powermate 11 Gallon Air Compressor

2 Answers

Sparking brushes

try blowing out motor i have used a armature cleaner like acetone while motor is unplugged or just replace brushes

Jun 26, 2009 | Coleman Powermate 60 Gallon Air Compressor

1 Answer

I need motor brushes for campbell hausfeld WL611105AJ air comp.

If you can find a match to the brushes that came out of the motor they will work. When I say match, I mean the size. Height, width and depth, length only needs to be close to allow for wear over time. The longer the brush the more wear you will get. If you can't find the exact size then you can always file a larger brush to fit. I just had to do that for a small motor in my shop-vac, works great. Also another consideration is how the line coming off the back of the brush connects to the Stator. If you can't match the connector soldering it is fine or crimp the appropriate connector to it. Beyond those two elements brushes are pretty much the same.

Your biggest problem is finding an assortment of brushes. Some hardware stores will carry some, (check the bins with all the small nut, bolts and other connectors), also automotive parts stores carry them, (for alternators),. Your best bet would be an electric motor repair shop.
Good luck

Apr 15, 2009 | Dewalt 2 Hp 4 GAL Air Compressor

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